Method of constructing a wall or fence with panels

ABSTRACT

This invention relates generally to a method of constructing walls or fence systems from panels. More particularly, the invention relates to constructing such walls or fence systems wherein a back face of one panel connects to a back face of another panel and further wherein the front faces of the panels have a desirable texture and further wherein a concrete footing of the wall or fence system is poured after courses of panels have been stacked one upon the other.

This application claims the benefit of U.S. Provisional Application No.60/989,295, filed Nov. 20, 2007, entitled “Method of Constructing a Wallor Fence with Panels”, the contents of which are hereby incorporated byreference herein.

FIELD OF THE INVENTION

This invention relates generally to a method of constructing walls orfence systems from panels. More particularly, the invention relates toconstructing such walls or fence systems wherein a back face of onepanel connects to a back face of another panel and further wherein thefront faces of the panels have a desirable texture and further wherein aconcrete footing of the wall or fence system is poured after courses ofpanels have been stacked one upon the other.

BACKGROUND OF THE INVENTION

Generally, free-standing block walls or fences are constructed ofconcrete blocks (or similar material) in running courses. A trench isusually dug and a concrete footing is prepared by the placement ofbatter or screed boards to define the width and thickness of thefooting. Horizontal reinforcing material, such as steel, running bothlaterally and transversally is tied together forming a cage within thescreed board framework. The reinforcing material cage generally hasvertical support elements that protrude above the screed board frameworkand are used to connect to the vertical wall structure. Concrete is thenpoured into the screed board framework and is leveled off so that it isflush with the screed surface. This leveling process can be difficult toachieve when working around the vertical support elements. The concreteis generally allowed to set for a time and then later a first course ofblocks is laid using mortar to level the blocks on the concrete footing.Due to the irregularity of the footing with all the vertical supportelements protruding through it, the first course usually requires theuse of mortar at the bed and head joints of the blocks in order toensure that it is level. Typically each subsequent course is placed insuch a manner so that the vertical joints between blocks are staggeredin a running bond pattern from a previous course. Mortar is used as abinding agent between the courses and between the ends of each of theblocks. Conventional concrete blocks typically have one or more voids orcores extending through them in the vertical direction to create openvertical columns through the walls. The vertical support elements areaccommodated within these vertical columns. The blocks are installedover the vertical support elements. The cores or voids are filled withmasonry (concrete) grout to connect the wall to the vertical supportelements of the footing to help ensure that the wall and footing performas a structure in resisting lateral moment loads. Additional reinforcingbars may be placed in these columns for enclosure with concrete groutwithin the columns, in accordance with building code standards and areconnected to the vertical support elements of the footing to help ensurewall stability.

In order for a wall constructed in this manner to be approved, abuilding inspector normally will require what is known as a “knockout”.A “knockout” is an inspection opening in a wall block at or near thebase course. This requires that a portion of a block be removed in orderto visibly ensure that the concrete grout has fully filled the entirevertical column.

Another widely accepted method of construction of such walls is to drystack concrete wall units, or blocks. Mortar is not used in this method.These blocks are popular because they are mass produced and,consequently, relatively inexpensive. They are structurally sound andeasy and relatively inexpensive to install. Because they compriseconcrete, they are durable. They can be given a desired appearance, forexample by using coloring and textures to simulate natural stone and/oradding a real or cultured stone veneer. Many block systems also use pinsthat are adapted to fit in corresponding pin holes in adjacent blocks ormay use other mechanical means to contribute to the alignment andstability of a wall.

Typically, retaining wall blocks are manufactured to have the desiredappearance on the front face (i.e., the outer face of a wall) becauseonly the front is visible after the wall is constructed. It is highlydesirable to have the front face of the wall system have a natural stoneappearance, and many approaches are used in the art to treat or processconcrete to evoke the appearance of natural stone, including splittingthe block, tumbling the block to weather the face and edges of the face,and using processing or texturing equipment to impart a weathered lookto the concrete.

Depending upon their location, the soil type, the amount of water thatcan flow through the wall, and the mineral content of the water, anundesirable appearance (efflorescence) can develop on the surface of aretaining wall. Efflorescence refers to the leaching of mineral saltsfrom water and this often occurs on walls in contact with water. Theresultant deposit on a surface creates an unattractive white stainedappearance on a wall. In addition, due to exposure to the elements andfreeze/thaw cycles, concrete retaining walls may exhibit spalling, thatis, chipping and cracking of concrete, which affects their appearanceand can ultimately affect their utility. Freeze-thaw effects areworsened when the wall face is exposed to salt spray, which commonlyoccurs on roadways where de-icing salts are used to clear the road ofice and snow.

There have been prior efforts to veneer segmental retaining walls withnatural stone or concrete that is molded to closely resemble naturalstone. While such veneering produces aesthetically pleasing walls, it isa laborious and highly expensive process, as it requires skilled masonrywork to tie in the stone or concrete veneer to the wall usingtraditional mortared masonry construction methods. Such veneering candouble the cost of the finished wall. In addition, segmental retainingwalls are not rigid structures and applying a rigid mortared veneer maycause cracking if the non-rigid underlying segmental wall moves, unlessappropriate steps are taken to provide slip joints.

High density structural poly foam can be utilized to create panel formsof accurate dimensions and shape. Poly foam panels are relativelylightweight (approximately 1 lb/sq foot area, that is 1 to 2 inchesthick). The material is easy to handle due to its lightweight, can beshipped easily long distances, and is durable and long lasting. Themolds to produce the high density structural poly foam panels can bemade to make a wide variety of shapes and sizes thus offering a widerange of styling and geometry.

SUMMARY OF THE INVENTION

This invention relates generally to a method of constructing walls orfence systems from panels. More particularly, the invention relates toconstructing such walls or fence systems wherein a back face of onepanel connects to a back face of another panel and further wherein thefront faces of the panels have a desirable texture and further wherein aconcrete footing of the wall or fence system is poured after courses ofpanels have been stacked one upon the other.

The invention provides a method for constructing a wall or fencecomprising: providing a plurality of connectors and a plurality ofpanels, each panel having a front face and an opposed back face, a setof opposed and substantially parallel upper and lower surfaces and firstand second opposed and substantially parallel side surfaces; preparing alevel base; forming a base layer of panels on the level base by placingopposed panels on the level base and connecting a back face of at leastone first panel of the base layer to a back face of at least one opposedsecond panel of the base layer with at least one connector, the frontfaces of the at least one first panel and the at least one second panelfacing outward, the at least one first panel and at least one secondpanel each having a knockout cavity; placing at least one course ofopposed panels on the base layer of panels and connecting a back face ofat least one first panel of the at least one course to a back face of atleast one opposed second panel of the at least one course with at leastone connector, the front faces of the at least one first panel and theat least one second panel of the at least one course facing outward, toform a top surface of an uppermost course of panels; and pouring aflowable material from the top surface between the opposed panels toform a support footing for the wall or fence, the support footingencasing at least a portion of the base layer of panels. In anembodiment, the method further comprising: forming a trench; and addingbase material to the trench, wherein the step of preparing a level basecomprises leveling the base material in the trench. In an embodiment,the base material is compacted granular material or crushed stone. Inone embodiment, the flowable material is concrete or cement.

In one embodiment, the method further comprises: after placing aplurality of panels and prior to pouring the flowable material, forminga reinforcing framework between opposed panels, the reinforcingframework including vertical reinforcement members. In an embodiment, atleast one vertical reinforcement member is L-shaped and has a verticalportion and a perpendicular leg portion, the perpendicular leg portionprotruding outwardly through a knockout cavity, the perpendicular legportion being encased in the support footing after the flowable materialis poured. In an embodiment, the reinforcing framework includeshorizontal reinforcement members. In one embodiment, the panels of thebase layer and the panels of at least one course have the samestructure. In an embodiment, the at least one connector that connectsthe at least one first panel and the at least one second panel of thebase layer also connects the at least one first panel and the at leastone second panel of the adjacent course of panels. In an embodiment, theconnector has at least four dovetail projections. In one embodiment, thepanels are made of polyfoam.

In one embodiment, the support footing encases at least one half of avertical height of the base layer of panels, and in another embodiment,the support footing substantially encases the base layer of panels. Inan embodiment, each set of opposed panel surfaces has mating tongue andgroove attachments, respectively, so that a respective tongue attachmentand groove attachment of adjacent panels connect the adjacent panels. Inone embodiment, the back faces of the panels have dovetail channels. Inan embodiment, at least one horizontal reinforcement member rests on atleast one connector. In one embodiment, at least one verticalreinforcement member passes through a vertical support ring that is partof at least one connector.

In one embodiment, the at least one first panel of the at least onecourse and the at least one opposed second panel of the at least onecourse have a pattern molded into their front faces. In embodiments ofthe invention, the pattern is an ashlar pattern, a boulder rock pattern,or a ledge rock pattern.

In one embodiment, the method further comprises attaching a cappingblock onto a top of the wall or fence. In an embodiment, the methodfurther comprises attaching an end wall block to some of the pluralityof panels before pouring the flowable material.

The invention provides a wall or fence comprising: a support footingformed from a hardened flowable material; a base layer of opposedpanels, at least a portion of the base layer of panels being encasedwithin the support footing, a back face of at least one first panel ofthe base layer being connected to a back face of at least one opposedsecond panel of the base layer with at least one connector, the frontfaces of the at least one first panel and the at least one second panelfacing outward, and the at least one first panel and at least one secondpanel each having a knockout cavity, and a plurality of courses ofopposed panels placed on the base layer of panels, a back face of atleast one first panel of the at least one course being connected to aback face of at least one opposed second panel of the at least onecourse with at least one connector, the front faces of the at least onefirst panel and the at least one second panel of the at least one coursefacing outward, a volume between the opposed panels containing thehardened flowable material. In an embodiment, the hardened flowablematerial is concrete or cement. In one embodiment, the wall or fencefurther comprises a reinforcing framework between opposed panels, thereinforcing framework including vertical reinforcement members. In anembodiment, at least one vertical reinforcement member is L-shaped andhas a vertical portion and a perpendicular leg portion, theperpendicular leg portion protruding outwardly through a knockoutcavity, the perpendicular leg portion being encased in the supportfooting. In an embodiment, the reinforcing framework includes horizontalreinforcement members. In one embodiment, the panels of the base layerand the panels of the plurality of courses have the same structure. Inan embodiment, the at least one connector that connects the at least onefirst panel and the at least one second panel of the base layer alsoconnects the at least one first panel and the at least one second panelof an adjacent course of panels. In one embodiment, the panels are madeof polyfoam. In one embodiment, the thickness of the wall or fenceterraces from wider to narrower as the wall heightens.

It is to be understood that both the foregoing general description andthe following detailed description are exemplary and explanatory and areintended to provide further explanation of the invention as claimed.

BRIEF DESCRIPTION OF THE DRAWINGS

A preferred form of the present invention will now be described by wayof example with reference to the accompanying drawings, wherein:

FIGS. 1A and 1B illustrate perspective views of a panel mold embodimentof the present invention.

FIG. 1C illustrates a perspective view of an alternate panel moldembodiment of the present invention.

FIGS. 2A to 2C illustrate back, perspective and front views of a panelof the present invention.

FIG. 2D illustrates a back view of an alternate embodiment of the panelof FIGS. 2A to 2C.

FIGS. 3A and 3B illustrate perspective views of third and fourthembodiments of the panel of the present invention.

FIGS. 4A, 4B and 4C illustrate front views of second, third and fourthembodiments of front faces of the panel of the present invention.

FIG. 5A illustrates a perspective view of a connector of the presentinvention.

FIGS. 5B and 5C illustrate front and top views, respectively, of asecond embodiment of the connector of the present invention.

FIG. 5D illustrates a front view of a third embodiment of the connectorof the present invention.

FIGS. 5E and 5F illustrate perspective and bottom views of a fourthembodiment of the connector of the present invention.

FIGS. 6A to 6C illustrate side, front and perspective views of a wallmade from the panel system of the present invention.

FIGS. 6D and 6E illustrate partial cut-out perspective views of firstand second embodiments of walls formed using the panels and panel systemof the present invention. 6F illustrates a side view of the tongue andgroove connection of the panel wall system of the present invention.

FIG. 6G illustrates a top view of the dovetail projection of a connectorattaching to a dovetail channel of a panel for the panel wall system ofthe present invention.

FIG. 6H illustrates a side view of the tongue and groove connection ofan alternate embodiment of the panel of the present invention.

FIGS. 7A and 7B illustrate top views of a corner of walls made fromfirst and second embodiments of corner panels of the panel system of thepresent invention.

FIGS. 8A and 8B illustrate top views of pilasters or columns made fromfirst and second embodiments of pilaster panels of the panel system ofthe present invention.

FIGS. 8C and 8D illustrate top views of pilasters or columns made fromthird and fourth embodiments of pilaster panels of the presentinvention.

FIGS. 9A and 9B illustrate top views of ends of walls made from firstand second embodiments of end panels of the panel system of the presentinvention.

FIGS. 10A to 10H illustrate side views of various embodiments of cappingpanels of the panel system of the present invention.

FIG. 11A illustrates a front view of a finished wall of the presentinvention showing a running bond configuration.

FIG. 11B illustrates a front view of a finished wall of the presentinvention showing a stacked bond configuration.

FIG. 11C illustrates a front view of a wall of the present inventionshowing a wall terracing with the slope of the grade.

FIG. 11D illustrates a side view of a wall of the present inventionshowing a partial retaining wall that terraces with the height of thewall.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

This invention comprises panels that are used together in theconstruction of a wall. The panels are configured to be compatible witheach other in the construction of a partial retaining wall, a parapetwall, a free-standing wall, a sound wall or a fence system. Such wallsmay be straight and may have corners and 90 degree angles. Although nota requirement of this invention, each panel may have at least one facethat is textured in a manner resulting in the appearance of naturalstone. Preferably, there is a natural-appearing finish on all exposedsides of the wall. The wall system is designed to be structurally soundand easy to install.

It is to be emphasized that the surface of a panel may be molded to haveany desired appearance. A natural appearance, such as stone, isgenerally most desirable. The panel may have a uniform appearance or itmay have an ashlar pattern formed into it. The panels may also resemblestone that has been processed or treated as is commonly known in thenatural stone industry. For example, the panel may resemble weatheredstone, polished stone or flame treated stone. In addition, the mold maybe configured to produce panels that resemble stone that has been handor machine pitched or tumbled to produce an aesthetically pleasingnatural quarried stone appearance.

The panels are produced in dimensions that are convenient to manufactureand handle. The panels are substantially planar. Convenient panel sizesmay have a height of 12 inches (30.5 cm) and a length of 48 inches(121.9 cm), another convenient size are panels that have a height of 24inches (61 cm) and a length of 48 inches (121.9 cm). These panels arelight weight, relatively large, durable, weather resistant and easy tohandle. The dimensions of the panel may vary from these stateddimensions in order to meet aesthetic or functional requirements ofparticular applications. The panel can be composed of fiberglass,concrete, wood, particle board, plastic, etc. but is preferably composedof a high density structural polymer foam. Some examples of suitablepolymers that may be utilized to create the high density structuralpolymer foam are disclosed in U.S. Pat. Nos. 6,607,683 B1 and 7,235,204B2 both to Harrington and consist of urethanes, phenolics, epoxies,alkyds, allylics, aminos, polyesters and silicones. The polymer foam isusually of a pre-selected color and injected into a mold that mayadditionally have a surface oxide coating to give the polyurethane foama more visually appealing appearance as well as resistance to thenatural elements of U.V. sunlight deterioration, water, ice, etc. Thepolymer foam preferably is durable, weather resistant, light weight andeasy to handle. High density structural polyurethane foam can be used tocreate panels of accurate dimensions and shapes. These panels can betextured by forming in molds that have been made to simulate true stoneand stone patterns. Color can be added that provides further naturalappearance and resistance to U.V. degradation. The various finishes andmolded textures that can be formed from the polymer foam visuallyenhances the panel and makes it look like real stone. The panel can bemade with poly foam that is flame and ignition resistant. The density ofthe poly foam can be varied with filler materials to increase durabilityand hardness and to further resist impact damage.

A back face of the panel preferably is provided with single or multipleelevated columns which include structure for attaching a connector. Forexample the columns may contain dovetail channels that have been moldedor routed into the elevated column. The dovetail channels of the panelcan be affixed to an attachment means such as a connector as describedin more detail below. The polymer foam composition of the panels allowsthe channel to be molded into the panel when it is formed or cut to aprecise location and size (post-forming). In one embodiment the backface of one panel may be attached to the back face of one or moreopposing panels with the connector. The connector may protrudevertically from the top of the panel and can engage the back faces ofopposing panels in another course of a wall or fence adding to thestructural integrity and support of the structure. The subsequentcourses of panels may be offset from the previous course in a runningbond pattern or stacked directly on top of the previous course dependingon the desired look of the structure. In another embodiment, the mirrorimage back faces of opposing and non-offsetting first and second panelsare attached to one or more connectors to form a panel block. This panelblock can be assembled at the site of the construction of the structurebeing built and is easy to handle and work with. Alternately, panels maybe attached to alternate attachment means and affixed directly to apreexisting structure such as a wall or fence without the need to form apanel block. The poly foam panel can be attached to block faces onexisting retaining walls and other structures as well to give thestructure a more desirable appearance. It would also be beneficial toattach the poly foam panels of the present invention to an efflorescedstructure that is still structurally sound in order to improve theoverall aesthetic quality of the structure. Such alternate methods ofattachment are described in detail in U.S. Patent Application Ser. No.60/945,457 (Veneers for Walls, Retaining Walls, Retaining Wall Blocks,and the Like) and U.S. Patent Application Publication No. 2005/0252144A1 (Veneers for Walls, Retaining Walls and the Like), both herebyincorporated herein by reference. A spacer may be placed between thepoly foam panel and the surface it is being affixed and/or a backsurface of the poly foam panel may be given a corduroyed texture thatwould be beneficial by allowing drainage and any efflorescence thatoccurs in the structure to flow down open air space cavities andchannels between the back surface of the panel and the surface of thestructure where it would not affect the aesthetic quality of the panelcovered structure.

In a preferred embodiment, the panels are additionally provided withtongue and groove attachment means so that two adjacent panels can beconnected to each other. Preferably, each panel has two adjacent sideswith a groove adapted to receive a tongue from corresponding sides ofadjacent panels. Preferably, the attachment means provide a joint thatdiscourages or minimizes penetration of water from rain or roadwayspray. Optionally the groove may be molded or routed with a drip edge tofurther discourage collection and penetration of water into thestructure.

Panels of the present invention used in the production of a structuresuch as a wall or fence may be supported with a concrete footing. Thewall or fence may be further reinforced with vertical reinforcingmembers that may be located in vertical cavities created by the spatialvoid between the opposing panels of the wall, and/or horizontalreinforcing members located in horizontal channels within the connectorsattached to the back faces of the panels of the wall to form areinforcing framework. In order to form the footing, concrete may bepoured from the top of the structure into the cavities created by theopposing panels spaced apart the distance of the connector. The concreteflows down through the cavities and out through knockout cavities at thebottom surface of the structure. The concrete covers a footing frameworkto a pre-determined depth and encases the vertical and horizontalreinforcing members to form a support structure for the wall asdescribed further in U.S. Patent Application Ser. No. 60/928,466 (Methodof Constructing a Block Wall) hereby incorporated herein by reference.

Turning now to the Figures, the panel wall system of this invention isshown and described.

FIGS. 1A and 1B illustrate a first embodiment of a mold used to form apanel of the present invention. Panel mold 20 has top plate 22 hinged tobottom plate 23. When in the closed position shown in FIG. 1A the topand bottom plates form a substantially enclosed mold cavity. The innersurfaces of top plate 22 and bottom plate 23 have been designed toimprint a desired surface texture onto front and back faces of thepanel. Groove inserts 28 and 29 can be placed into front 25 and side 27of the panel mold to form the groove of the panel. The tongue of thepanel on adjacent sides opposite the groove sides is formed within achannel 24 defined between the top and bottom plates. Note that forpurposes of illustration a portion of the panel has been removed and oneside of the panel mold is shown in section. Although not shown it willbe understood that the removed portion forms channel 24 between the topand bottom plates to form a tongue along the side of the panel. Whenforming the panel polymer foam in its liquid state is placed in ametered amount into the mold. Slideable channel inserts 21 are sprayedwith a release agent, along with the groove inserts and the innersurface of the top plate and then channel inserts 21 are slid into topplate 22. The release agent functions to lubricate the surfaces so thepanel can be more readily stripped from the mold after the panel hasformed and set in the mold by restricting the ability of the polymerfoam to bond to the surfaces of the mold. After the polymer form hassufficiently hardened, channel inserts 21 are withdrawn to enable thehardened polymer panel to be removed from the mold. Alternatively, thedovetail channels of the elevated column may be routed into the panelafter the panel has been removed from the mold and after the polymerfoam has set and hardened. It should be further understood that only aportion of the panel mold boxes are shown in FIGS. 1A and 1B. Additionaldovetail channel forming members may be included in the removedportions. Additionally, any number of dovetail channels may be formedwithin each plate. FIG. 1B illustrates a silicone liner 26 whichimprints the desired pattern of the front face onto the panel andfunctions to give the front face of the panel a more natural stoneappearance as desired.

FIG. 1C illustrates an alternate embodiment of a panel mold of thepresent invention. Panel mold 30 has top plate 32 hinged to bottom plate33. The inner surfaces of top plate 32 and bottom plate 33 have beendesigned to imprint the desired surface texture onto front and backfaces of the panel. Groove inserts 38 and 39 can be placed into thefront 35 and side 37 of the panel mold to form the groove of the panel.In this embodiment the dovetail channels are formed by channel inserts31 which are slideably accommodated in grooves formed into the topsurface of top plate 32. The channel inserts include wedge shaped barswhich extend into the mold cavity. The width of the bars is greateralong the surface closer to the center of the mold cavity. Channelinserts 31 are coated with a lubricating release agent and placed intothe top plate of the mold when the polymer foam is placed into the mold.The polymer foam hardens around the channel inserts and when the foamhas set the channel inserts are slid out of the mold box formingdovetail shaped channels and the panel is stripped from the mold. Therelease agent enables the coated channel inserts to be more readilyremoved from the mold by restricting the ability of the polymer foam tobond to the channel inserts.

The panel molds of FIGS. 1A to 1C can be used in a method of making apanel as follows. (1) “Clean store” area. The mold is stored clean andin a ready to use condition. (2) Color stage. Oxide colors are placedinto the silicone liner of the bottom plate and are then brushed intothe silicone liner beds. (3) Spray sealer stage. This locks in the oxidecolors. (4) Temporary drying station for sealer. (5) Polymer applicationstage. A metered amount of the high density structural polyurethane foamis placed in its liquid state by a manual or robotic method into themold. (6) The top plate and the groove inserts of the mold are sprayedwith a release agent and the top plate is then closed. The top andbottom plates are then clamped together. As the polymer foam expands andhardens, the top plate does not dislodge from the bottom plate and ruinthe panel as it forms in the mold. Channel inserts are sprayed with arelease agent and slid into the mold. (7) Cure area. The mold is allowedto cure for approximately 20 minutes and the cure area may hold up to 60molds. (8) The molds are pulled out of the cure area and are prepped fordemolding. (9) Channel and groove inserts are removed. (10) The mold isunclamped and the top plate is opened. (11) The cured panel is demoldedand the silicone liner is stripped from the panel and re-inserted intothe bottom plate. (12) The mold is cleaned and checked before placingback into the “clean store” area. (13) De-buffing stage. Any excessflash is removed at panel edges. (14) Rout out stage. If channel insertswere not used to create dovetail channels, the dovetail channels can berouted into the panel. Grooves and other desired features of the panelmay also be routed if not formed into the panel. (15) Color touch up asrequired prior to packaging. (16) Packaging station. This stationprovides protective wrap to panel or between panels and places panels inbox. (17) Assemble shipping/distribution pallet. Boxes are placed on apallet into a complete cube. The pallet is then stretch wrapped andplastic banded. (18) Completed pallets are then placed into inventorywith clearly labeled boxes and pallet signs.

FIGS. 2A to 2C illustrate back, perspective and front views respectivelyof panel 100 a of this invention. The panel comprises opposing andsubstantially parallel upper and lower surfaces 102 and 104respectively, and opposing and substantially parallel side surfaces 110and 112. The panel also comprises front and back faces 106 a and 108 a,respectively. Front face 106 a and rear face 108 a each extend from topsurface 102 to bottom surface 104 and side wall surfaces or ends 110 and112 each extend from top surface 102 to bottom surface 104 and fromfront face 106 a to rear face 108 a. Back face 108 a has elevatedvertical columns 120 a, 120 b, 120 c, 120 d, 120 e, and 120 f andelevated horizontal reinforcing ribs 130 forming a grid-like frameworkwhich protrudes from back face 108 a and functions to add support andrigidity to the panel and the wall formed therefrom and also helps toprevent bowing. Elevated columns 120 b, 120 c, 120 d and 120 e eachcontain a dovetail channel or slot 122 which engage and secure to thedovetail projections of connectors 450 a and 450 b as described below.Elevated columns 120 b, 120 c, 120 d, and 120 e function to strengthenthe attachment to the connectors of the panel wall system. The dovetailchannels or slots 122 may be routed into the elevated columns or may bemolded during production. Arched knockout indentations 190 may be moldedinto the back face of the panel. Arched knockout indentations 190provide a indented guideline on the back face of the panel for theoptional production of knockout cavity 195 described below. Tongues 132and 134 project outwardly from top surface 102 and side surface 112,respectively and may be slightly tapered. Grooves 136 and 138, which canbe molded or routed into the poly foam, project inwardly from bottomsurface 104 and side surface 110, respectively. The tongue of a firstpanel is designed to engage and secure with the groove of a secondadjacent panel thereby interlocking the panels and adding to thestructural integrity and visual appeal of the wall or fence. Aconvenient panel height of 12 inches (31.5 cm) and a length of 48 inches(121.9 cm) is shown but these dimensions may vary due to the desiredaesthetics or manufacturing and construction efficiencies.

FIG. 2D illustrates the back face of panel 100 b, a further embodimentof the invention. Panel 100 b has additional reinforcing ribs 130, noarched knockout indentations and a height of 24 inches (61 cm) and alength of 48 inches (121.9 cm). It is to be noted that the dimensions ofthe panels could vary depending on the particular application and arenot limited to the two dimensions supplied above.

FIG. 3A illustrates back face 208 of panel 200 of the present invention.Panel 200 has two elevated columns 220 which protrude from back face208. Each column contains two dovetail channels or slots 222 whichengage and secure to the dovetail projections of connector 450 or 550 asdescribed below. Elevated columns 220 add rigidity and support tovertically reinforce the panel to prevent bowing and also function tostrengthen the attachment to connectors 450 or 550. Reinforcing ribs 230are formed during the mold process and protrude horizontally from backface 208.

FIG. 3B shows back face 308 of panel 300 of the present invention. Panel300 is similar to panel 200 except that elevated columns 320 eachcontain a single dovetail channel 322.

FIGS. 4A to 4C illustrate front views of alternate embodiments of thefront face of the panels of the present invention. FIG. 4A illustratesan ashlar pattern molded onto front surface 106 b of the panel. FIG. 4Billustrates a boulder rock pattern molded onto front surface 106 c ofthe panel and FIG. 4C illustrates a ledge-rock pattern molded onto frontsurface 106 d of the panel. It should be noted that the patterns shownare not limiting and that various other patterns could be imprinted ontothe front surface of the panel in order to achieve a desired visualappearance.

Connector 450 a as shown in perspective in FIG. 5A and connector 450 bas shown in front and top views in FIGS. 5B and 5C, have dovetailprojections 452 configured to engage and secure to a dovetail channel ofthe back face of the panels of the present invention. Dovetailprojection 452 may also be formed with a gusset or web located withinthe dovetail of the projection for added stability. Connectors 450 a and450 b also have angled truss supports 454 which add stability andrigidity to the connectors and to a wall formed from the connector andpanels attached thereto. The connectors are provided with a ledge 456 tosupport the horizontal reinforcing members 80 as described below.Connector 450 a has reinforcing tab 457 which creates two separatechannels on ledge 456 which further help to separate, secure and holdthe horizontal reinforcing members 80 used in the framework of the wallsupport. The connector can be made of an injection molded plastic,metal, wood or other convenient material. The connector may also besized to extend the entire height of the panel or may extend the heightof two or more panels in order to additionally interconnect courses ofpanels. FIG. 5D illustrates connecter 450 c and is similar to connectors450 a and 450 b but has been made to correspond to the panel height ofwhich it is connecting, thus allowing for the remote assembly of 2 facepanels and a connector to form a panel block as described previously.These blocks can then be assembled into a wall or other structure. Thisconnector also allows for the placement of additional horizontalreinforcing members to further stabilize and strengthen the structure.

FIGS. 5E and 5F illustrate an alternate embodiment of a connector of thepresent invention. Connector 550 has dovetail projections 552 a, 552 b,552 c and 552 d which extend outwardly from side walls 562 and 564.Projections 552 a to 552 d may contain vertical friction ribs 590 thathelp secure the projections into the dovetail channels of the panels.Vertical friction ribs may also be used on other variations ofconnectors as so desired. Side wall 566 contains horizontal reinforcingchannels 556 a and 556 b and side wall 568 contains horizontalreinforcing channels 556 c and 556 d. Vertical support ring 560 which isconnected to the inside corners of each side wall by bridge 570 a, 570b, 570 c, and 570 d is used to secure, guide and support the verticalreinforcing members of the framework of the wall support as discussed indetail below. The connector can be made of an injection molded plastic.The connectors illustrated in FIGS. 5E and 5F are designed to be usedwith a panel having columns formed with two dovetail channels such aspanel 200 with back face 208 as illustrated in FIG. 3A. Dovetailprojection 552 of connectors 550 are received in dovetail channels 222of back faces 208 of panels 200. The dovetail projections of eachconnector 550 engage both dovetail slots for each elevated column. Theremay be single or multiple connectors 550 engaged and secured to thedovetail channels of each elevated column. This connection secures thetwo panels to one another while leaving a predetermined distance thewidth of connector 550 between the two faces.

Referring now to FIGS. 6A to 6H, a method of constructing a freestandingwall or fence 600 with a wall system which includes a plurality ofpanels 100 a and a plurality of connectors 450 b will be described. FIG.6A illustrates a side view of an excavated trench T of a pre-selecteddepth, which has been dug into soil S and lined with a level base B ofcompacted granular material such as crushed stone. Depending upon thesoil conditions the trench can be dug to the exact size needed for thefooting of the desired structure and wherein the walls of the trenchacts like form boards for the footing. It should be noted that this isnot limiting and that the trench can be dug to any specification andthat form boards can be used to form the footing to desiredspecifications. A base layer 10 is formed by attaching the back face 108a of panel 100 a to the back face of an opposing panel 100 a withconnector 450 b whereby the dovetail projections 452 of connector 450 bare received in opposing dovetail slots 122 of the back faces 108 a ofpanels 100 a as shown in FIG. 6G. This connection secures the two panelsto one another while leaving a predetermined distance the width ofconnector 450 b between the two faces. This distance is determined bythe connector span between the two opposing panels and is a function ofthe structure's strength. The thicker the core of the structure beingbuilt, the more height or lateral load can be subjected on thestructure, allowing the wall to be built taller due to the thicker wallcross-sections with wider concrete dimensions. It may also be beneficialto build a structure with varying and terracing widths from wider tonarrower the higher the structure is built especially if the thickerwall cross-sections are not necessary for structural stability over thefull height of the wall as illustrated in the partial retaining wall ofFIG. 11D. The back face of one panel may be offset from the back face ofan opposing panel thus attaching the panel to the back faces of twoopposing panels. Alternatively, the back faces of opposing panels may bealigned. The base layer is leveled onto the granular material of theexcavated trench. Arched knockout indentations 190, which areindentation guides for the panel assembly and construction crew, areremoved from the panels used to form the base layer, forming knockoutcavities 195. It should be understood that if the panel being used inthe formation of the wall does not have arched knockout indentations 190for producing knockout cavities 195, knockout cavities may be cut intothe panel being used on site or the base layer could be laid withspatial gaps between adjacent panels. The panels 100 a of base layer 10are placed so that the lower surfaces of the panels lay directly on topof the granular material.

A first course 20 of panels is then stacked upon the base layer 10panels. Panels 100 a of first course 20 are placed end to end upon baselayer 10. Connector 450 b protrudes vertically from the base layer andengages opposing back faces 108 a of the first course interlocking thetwo courses together as shown in FIG. 6D. It should be noted that thepanels may be stacked or offset from the previous course. The side walltongue or grooves of each block secure into the tongue or groove of thenext adjacent panel when placed end to end and also engage the tongue orgroove of the panel of each previous course adding additional supportand interconnecting of the panels as shown in FIG. 6F. FIG. 6Hillustrates a tongue and groove of a panel wall system whereby the panelhas been molded with a drip edge 197 to further discourage collectionand penetration of water into the structure. Subsequent courses ofpanels are laid the same way as the base layer and first course exceptthat the arched knockout indentations are not removed above anyelevation where foundation/footing elements will be formed. Two rows ofhorizontal reinforcement members 80 are placed parallel onto ledge 456of connector 450 b. Horizontal reinforcement members 80 can be placedonto the first course of panel wall 600 and then added at otherlocations as desired or in accordance with the requirements of the wallbeing built. For example, subsequent horizontal reinforcement membersmay be placed on every course, every other course, or any combinationthereof. Additional courses of panels are stacked one upon another andattached to opposing panels by connector 450 b until the desired heightis reached. If the desired height of the wall is reached and theconnector vertically protrudes from the last course of panels, theconnector may be cut to the desired height. It should be noted that incourses where the panel wall structure retains earth on one side, or thewall structure requires being built to code specified frost depth, thena non-textured (generally smooth), and/or non-colored, and/or nonsurface-oxide panel can be used below grade or where aesthetics are notcritical in order to reduce the cost of the overall structure. Analternate material, such as wood, metal, plastic, fiberglass concreteetc., may optionally be used in these circumstances as well to reduceoverall cost, as desired.

Vertical reinforcement members 90 are attached or tied to connector 450b (or if connector 550 were being used with panel 200, the verticalreinforcement member would be threaded through the vertical support ringof connector 550; or if connector 450 a were being used in combinationwith panel 200, the vertical reinforcement member would be placed intothe cavity created by the side to side placement of connectors 450 ainto the double slot dovetail channels of each elevated column of panel200). The vertical reinforcement members are preferably L-shaped, havinga perpendicular leg portion and a vertical portion. The perpendicularleg of vertical reinforcement member 90 is placed through the desiredopening and protrudes outwardly through knockout cavity 195 in thepanels of base layer 10 and is perpendicular to the first course asshown in FIG. 6B. The vertical reinforcement members can be insertedthrough the cavities during the laying of the first course or can beinserted during a later course, however they must be inserted before theperpendicular leg of the vertical reinforcement member can no longer beplaced or threaded through the knockout cavity of the panels of the baselayer. The desired height of the structure may be taller than thevertical reinforcing members themselves. In this case an additionalstraight vertical reinforcement member can be spliced onto or overlappedwith the initial or first stage vertical reinforcement member. Thehorizontal reinforcement members (two per course where required) areused to position and align the vertical reinforcement member in the opencore space or vertical column when placing the vertical steel into thewall after the wall has been assembled but before grouting. Thus therecan be much variation with the height of the structure. The 1 foot by 4foot dimension of one embodiment size of the panel of the presentinvention is ideal for creating a pattern of step down terracing in thelength of the structure to follow changing grade lines as shown in FIG.11C. Typically a change of 1 foot over 8 feet is average in a reasonableslope.

FIG. 6C is a perspective view of a wall and support footing frameworkfor the panel wall system of the present invention. The support footingframework includes horizontal footing reinforcing members 96 andtransverse footing reinforcing members 95. The perpendicular leg of thevertical reinforcement member is secured to the transverse footingreinforcing members 95. The transverse footing reinforcing membersprotrude outward on both sides of the knockout cavity in the panels ofbase layer 10 and are perpendicular to the first course of block.Horizontal footing reinforcing members 96 are secured to the transversefooting members and run parallel the length of the freestanding wall.The horizontal footing members and transverse footing members create afooting support framework that has been elevated above the granularmaterial by the height of rebar blocks 85 which are attached at variouspositions to the footing framework. The size of the rebar block can beselected to achieve a desired height in order to ensure proper placementof reinforcing members and footing specifications for supportrequirements and functions to help prevent the framework from corroding.The footing framework can be completed at anytime during the laying ofthe wall block courses. It may sometimes be beneficial to wait until allcourse layers have been laid so that block installers will not trip overthe framework during construction of the wall. It may also be beneficialto lay three or four initial courses and then complete the footing andsupport framework. Concrete could then be poured to encase the footingand support framework and then be allowed to set. This method would alsoleave unencumbered access along the wall as the construction workers arebuilding the remaining structure to the desired specifications.

The horizontal and transverse footing reinforcing members and thevertical and horizontal reinforcing members are selected of suitablediameter for structural support and integrity and can be made fromsuitable materials including but not limited to steel reinforcing bars(also referred to as “rebar”, which may be deformed, natural and/orgalvanized), threaded steel (galvanized) post-tension rods, fiberglassrods, and other reinforcing members that are suited for reinforcement inconcrete/masonry.

When a first desired height of the wall has been reached, typically 3 to4 panel courses, and the support footing framework is in place, and theends of the wall have been fitted with end wall blocks or end wallpanels as described below, concrete is poured into the top opening ofthe cavity created by the width of connector 450 b opposing the backfaces of panel 100 a. The concrete is poured from the top of the walland will fill the vertical cavity created by the vertical alignment ofthe side wall panels of the panel blocks. Weights, weighted spacer orconnector boards 70 may be placed on top of fittings 71 that are placedon the top surface of the wall as the concrete is poured into the cavityto ensure that the concrete does not cause the wall to float or rise.Additionally or alternatively the wall panels may be tied down to helpprevent any floating and to keep the panels from bowing under the weightof the wet concrete. The weight 70 may be any suitable material heavyenough to hold down the wall and the fitting 71 is designed to protectthe top surface and tongue of the last course of panels from the weight70. The concrete will flow down through the wall cavities or voids andout through knockout cavities 195 of base layer 10 until it fills thetrench and covers the footing framework to a predetermined depth andencases base layer 10 into a footing support structure as shown in FIG.6A. After the concrete has been poured and allowed to set for apredetermined time, more panel courses fitted with desired end panels orblocks of the structure may be laid, typically 3 to 4 panel courses, andmore support framework may be placed. Concrete is then poured to fillthe vertical cavity as described above. Again the same weight, fittingand tie downs may be employed to prevent the wall from floating orbowing. Additional courses can then be laid and the same steps repeateduntil the desired height of the wall has been reached. After theconcrete has been poured, any extra vertical reinforcing members thatextend above the last course of panels may be cut off (this could bedone before the concrete is poured into the columnar cavities) andcapping or coping block 40 (as described below) may be placed andsecured to the top surface of the last course. It should be understoodthat the three to four courses before each concrete pour is not limitingand in fact the whole structure may be built, or any number of coursesmay be laid before the concrete is poured depending upon thespecifications of the structure being built.

FIG. 6E shows an alternate embodiment of the panel wall system. In thisembodiment the wall panels and connectors are assembled to form aplurality of panel blocks. The panel blocks are laid in courses to forma wall in accordance with the previous discussion. For example, panelwall block 500 has been formed from opposing and non-offsetting panels100 b whereby the dovetail projections 452 of connector 450 b arereceived in mirror-image dovetail slots 122 of the back faces 108 b ofpanels 100 b. This connection secures the two panels to one anotherwhile leaving a predetermined distance the width of connector 450between the two faces. This panel block can be used to form a wall byplacing the panel blocks end to end in a course of the wall. The panelblock of an additional course may be offset from the previous course ormay be stacked directly vertical from the previous course. The panelblock system of building the wall can use the same vertical andhorizontal reinforcing framework and footing framework technique withconcrete pour as described herein.

FIGS. 7A and 7B illustrate top views of alternate embodiments of panelsfor the formation of corners for the present invention. FIG. 7A showsouter corner panel 701 and inner corner panel 702. Both corner panelshave elevated columns with dovetail channels to receive the connectorsof the present invention and tongue and grooves designed to engage otherpanels of the present system and may have horizontal ribbing. It shouldbe noted that both right handed and left handed inner and outer cornerpanels may be built from the same panels. FIG. 7B illustrates analternate embodiment of a corner whereby the outer corner is formed froma first panel 710 having tongue or projection 711 which engages a groove722 on the back face 721 of a second panel 720 and further whereby theinner corner is formed from a first panel 730 having tongue orprojection 731 which engages a groove 742 on the front face 741 of asecond panel 740. Panels 710, 720, 730, and 740 have elevated columnswith dovetail channels to receive the connectors of the presentinvention. It should be noted that both right handed and left handedinner and outer corner panels may be built from this kit of parts.

FIGS. 8A to 8D illustrate top views of alternate embodiments of panelsfor the formation of pilasters and columns for the present invention.FIG. 8A shows an embodiment of a pilaster or column with a wallprojecting from both sides. Panel 810 has groove 812 on front face 811and engages the tongue from panel 100 a of wall 600. Panel 820 hasgroove 822 on back face 823 and engages tongue 814 from panel 810. Panel830 has groove 832 on back face 833 and engages tongue 824 from panel820. Panel 830 has tongue 834 which engages the groove from panel 100 aof wall 600. Panels 810, 820 and 830 have elevated columns with dovetailchannels to receive connectors of the present invention. FIG. 8B shows asecond embodiment of a column or pilaster with panel 840 having groove842 and tongue 844 and is located on each side of the wall. FIG. 8Cshows a third embodiment wherein panel 100 a of wall 600 connects topanel 810, which connects to a first panel 820, which connects to asecond panel 820 and then to a third panel 820. Third panel 820 connectsto panel 830 which connects to panel 100 a of wall 600. Panels 810, 820and 830 have elevated columns with dovetail channels to receiveconnectors of the present invention. The connectors can be further wiredtogether to add additional support to the pilaster or column and toprevent the structure from bowing out when filled with concrete. FIG. 8Dshows a fourth embodiment wherein column or pilaster panel block 850having groove 852 and tongue 852 connects to panels 100 a of a wall.

FIGS. 9A and 9B illustrate top views of alternate embodiments of wallends for the present invention. FIG. 9A illustrates end wall block 901having tongue 902 and groove 903 and is designed to give the end of thewall a more finished appearance and to keep the concrete from seepingout the sides of the wall when it is poured. The end wall block ispreferably textured on all exposed sides. FIG. 9B illustrates an end ofa wall finished with panels. Panel 910 has groove 912 on side 911 andengages the tongue from panel 100 a of wall 600. Panel 920 has groove922 on back face 923 and engages tongue 914 from panel 910. Panel 930has groove 932 on back face 933 and engages tongue 924 from panel 920.Panel 930 has tongue 934 which engages the groove from panel 100 a ofwall 600. Panels 910 and 930 have elevated columns with dovetailchannels to receive connectors of the present invention.

FIGS. 10A to 10H show various embodiments of capping blocks or copingpieces for the present invention. FIGS. 10A to 10E show capping blocks40 a to 40 e respectively which have grooves 42 designed to engage thetongue from the panels of the present invention. These capping blockscan be further anchored to the wall or additionally attached with use ofan adhesive compound. FIGS. 10F to 10H show capping blocks 40 f to 40 hrespectively which have cavity 44 designed to fit over the tongues ofthe opposing sides of the wall. These capping blocks can be furtheranchored to the wall or additionally attached with use of an adhesivecompound.

FIG. 11A shows a finished section of the wall 1000 a of the presentinvention with a running bond pattern. The base layer of panels andfooter is shown in dash and is below grade. It should be noted that asingle course (the base layer) or more may be positioned below gradedepending upon the application. FIG. 11B shows a finished section of thewall 1000 b of the present invention with a stacked bond pattern. FIG.11C illustrates a front view of a wall 1000c of the present inventionshowing a wall terracing with the slope of the grade. FIG. 11Dillustrates a side view of a wall 1000 d of the present inventionshowing a partial retaining wall terracing from wider to narrower as thewall heightens.

Although particular embodiments have been disclosed herein in detail,this has been done for purposes of illustration only, and is notintended to be limiting with respect to the scope of the claims. Inparticular, it is contemplated that various substitutions, alterations,and modifications may be made to the invention without departing fromthe spirit and scope of the invention as defined by the claims. Forinstance, the choice of materials or variations in the shape or anglesat which some of the surfaces intersect are believed to be a matter ofroutine for a person of ordinary skill in the art with knowledge of theembodiments disclosed herein.

1. A method for constructing a wall or fence comprising: providing aplurality of connectors and a plurality of panels, each panel having afront face and an opposed back face, a set of opposed and substantiallyparallel upper and lower surfaces and first and second opposed andsubstantially parallel side surfaces; preparing a level base; forming abase layer of panels on the level base by placing opposed panels on thelevel base and connecting a back face of at least one first panel of thebase layer to a back face of at least one opposed second panel of thebase layer with at least one connector, the front faces of the at leastone first panel and the at least one second panel facing outward, the atleast one first panel and at least one second panel each having aknockout cavity; placing at least one course of opposed panels on thebase layer of panels and connecting a back face of at least one firstpanel of the at least one course to a back face of at least one opposedsecond panel of the at least one course with at least one connector, thefront faces of the at least one first panel and the at least one secondpanel of the at least one course facing outward, to form a top surfaceof an uppermost course of panels; and pouring a flowable material fromthe top surface between the opposed panels to form a support footing forthe wall or fence, the support footing encasing at least a portion ofthe base layer of panels.
 2. The method of claim 1, further comprising:forming a trench; and adding base material to the trench, wherein thestep of preparing a level base comprises leveling the base material inthe trench.
 3. The method of claim 2, wherein the base material iscompacted granular material or crushed stone.
 4. The method of claim 1,wherein the flowable material is concrete or cement.
 5. The method ofclaim 1, further comprising: after placing a plurality of panels andprior to pouring the flowable material, forming a reinforcing frameworkbetween opposed panels, the reinforcing framework including verticalreinforcement members.
 6. The method of claim 5, wherein at least onevertical reinforcement member is L-shaped and has a vertical portion anda perpendicular leg portion, the perpendicular leg portion protrudingoutwardly through a knockout cavity, the perpendicular leg portion beingencased in the support footing after the flowable material is poured. 7.The method of claim 6, wherein the reinforcing framework includeshorizontal reinforcement members.
 8. The method of claim 1, wherein thepanels of the base layer and the panels of at least one course have thesame structure.
 9. The method of claim 1, wherein the at least oneconnector that connects the at least one first panel and the at leastone second panel of the base layer also connects the at least one firstpanel and the at least one second panel of the adjacent course ofpanels.
 10. The method of claim 1, wherein the panels are made ofpolyfoam.
 11. The method of claim 1, wherein the support footing encasesat least one half of a vertical height of the base layer of panels. 12.The method of claim 1, wherein the support footing substantially encasesthe base layer of panels.
 13. The method of claim 9, wherein theconnector has at least four dovetail projections.
 14. The method ofclaim 1, wherein each set of opposed panel surfaces has mating tongueand groove attachments, respectively, so that a respective tongueattachment and groove attachment of adjacent panels connect the adjacentpanels.
 15. The method of claim 1, wherein the back faces of the panelshave dovetail channels.
 16. The method of claim 1, wherein at least onehorizontal reinforcement member rests on at least one connector.
 17. Themethod of claim 1, wherein at least one vertical reinforcement memberpasses through a vertical support ring that is part of at least oneconnector.
 18. The method of claim 1, wherein the at least one firstpanel of the at least one course and the at least one opposed secondpanel of the at least one course have a pattern molded into their frontfaces.
 19. The method of claim 1, wherein the pattern is an ashlarpattern.
 20. The method of claim 1, wherein the pattern is a boulderrock pattern.
 21. The method of claim 1, wherein the pattern is a ledgerock pattern.
 22. The method of claim 1, further comprising attaching acapping block onto a top of the wall or fence.
 23. The method of claim1, further comprising attaching an end wall block to some of theplurality of panels before pouring the flowable material.
 24. A wall orfence comprising: a support footing formed from a hardened flowablematerial; a base layer of opposed panels, at least a portion of the baselayer of panels being encased within the support footing, a back face ofat least one first panel of the base layer being connected to a backface of at least one opposed second panel of the base layer with atleast one connector, the front faces of the at least one first panel andthe at least one second panel facing outward, and the at least one firstpanel and at least one second panel each having a knockout cavity, and aplurality of courses of opposed panels placed on the base layer ofpanels, a back face of at least one first panel of the at least onecourse being connected to a back face of at least one opposed secondpanel of the at least one course with at least one connector, the frontfaces of the at least one first panel and the at least one second panelof the at least one course facing outward, a volume between the opposedpanels containing the hardened flowable material.
 25. The wall or fenceof claim 24, wherein the hardened flowable material is concrete orcement.
 26. The wall or fence of claim 24, wherein the wall or fencefurther comprises a reinforcing framework between opposed panels, thereinforcing framework including vertical reinforcement members.
 27. Thewall or fence of claim 26, wherein at least one vertical reinforcementmember is L-shaped and has a vertical portion and a perpendicular legportion, the perpendicular leg portion protruding outwardly through aknockout cavity, the perpendicular leg portion being encased in thesupport footing.
 28. The wall or fence of claim 27, wherein thereinforcing framework includes horizontal reinforcement members.
 29. Thewall or fence of claim 24, wherein the panels of the base layer and thepanels of the plurality of courses have the same structure.
 30. The wallor fence of claim 24, wherein the at least one connector that connectsthe at least one first panel and the at least one second panel of thebase layer also connects the at least one first panel and the at leastone second panel of an adjacent course of panels.
 31. The wall or fenceof claim 24, wherein the panels are made of polyfoam.
 32. The wall orfence of claim 24, wherein the thickness of the wall or fence terracesfrom wider to narrower as the wall heightens.